One-Piece Torque Plate Assembly for Even Disc Brake Pad Wear
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Solution Overview
Problem
Existing disc brake systems suffer from uneven brake pad wear, increased assembly time and cost due to the use of multiple fasteners, and susceptibility to corrosion at the junctions of the carrier and torque plate.
Innovation Solution
A disc brake system featuring a one-piece torque plate with integral mounting and carrier portions, where the carrier portion includes inboard and outboard pad supports that engage with the brake pads to distribute tension evenly, reducing the need for fasteners and simplifying assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multiple fasteners are used to assemble the carrier and torque plate, then the structural strength is improved, but the assembly time and cost increase
Solution Approach 1:
The carrier and torque plate are merged into a single integral component manufactured as one piece, eliminating the need for fasteners and multiple assembly steps while maintaining structural strength through continuous material geometry
2Strength
If multiple fasteners are used to assemble the carrier and torque plate, then the structural strength is improved, but the system cost increases
Solution Approach 1:
The carrier and torque plate are merged into a single integral component manufactured as one piece, eliminating the need for fasteners and multiple assembly steps while maintaining structural strength through continuous material geometry
Solution Approach 2:
The integral component is designed with distinct functional zones (mounting portion, carrier portion, pad supports) that are optimized for their specific functions while being manufactured as a single piece, reducing overall system complexity and cost
3Stability of the object's composition
If the carrier and torque plate are mechanically coupled with fasteners, then the positioning stability is improved, but the risk of corrosion at junctions increases
Solution Approach 1:
The carrier and torque plate are merged into a single integral component manufactured as one piece, eliminating the need for fasteners and multiple assembly steps while maintaining structural strength through continuous material geometry
4Force
If the brake pads are subjected to uneven pressure distribution, then the braking force is concentrated on the leading edge, but the pad wear becomes tapered and uneven
Solution Approach 1:
The pad support geometry is designed with varying characteristics along the pad length, with the leading end supported at a different height than the trailing end, creating a wedge effect that distributes pressure evenly across the entire pad surface during braking
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution reduces tapered pad wear, extends brake pad lifespan, simplifies assembly, reduces costs, and minimizes the risk of corrosion and joint slip during dynamic loading.
Implementation Method 1
The first and second bearing surfaces are configured to engage when the disc brake system is actuated such that at least a portion of the at least one inboard and/or outboard brake pads is put in tension
Data Source
AI summary
A disc brake system includes a torque plate having a mounting portion with an opening shaped to receive a vehicle axle and a carrier portion integrally formed with the mounting portion as a one-piece unit. The carrier portion includes an inboard leading pad support, an inboard trailing pad support, an outboard leading pad support, and an outboard trailing pad support. One or both of an inboard and/or outboard brake pad include a bearing surface engaged by a bearing surface on one of the pad supports when the disc brake system is actuated such that at least a portion of the at least one inboard and/or outboard brake pads is put in tension. At least one of the pad supports may include a slot defining the bearing surface. Methods of actuating and assembling the disc brake system are also disclosed.